Method of manufacturing cards that include at least one electronic unit

Abstract

The invention relates to a method for manufacturing boards that comprises depositing a liquid resin ( 22 ) on and/or under a plurality of electronic units for forming a plate defining a plurality of boards or board bodies. In order to do so, and in order to reduce as much as possible the residual air bubbles in the manufactured plate, the method comprises depositing the resin in the form of resin beads ( 26 ) initially having between them grooves ( 28 ) defining air discharge channels. The resin in uniformly spread using a pressing roller for one end of the plate to a second opposite end of the plate.

The invention claimed is: 
     
       1. A card manufacturing method wherein a plurality of cards or card bodies are made in the form of a plate or strip that includes a plurality of electronic units and a resin that at least partially coats the plurality of electronic units, wherein each card or card body is eventually cut out of the plate or strip, wherein the method includes the steps of:
 (a) providing a plurality of electronic units arranged on a working surface or a sheet; 
 (b) depositing at least one part of a resin in liquid form over the plurality of electronic units by a plurality of nozzles in a resin feed installation, wherein during deposition of the at least one part of the resin, the plurality of nozzles undergoes a movement relative to the plurality of electronic units along a first direction so as to generate strings of resin on the plurality of electronic units, wherein each deposited resin string has a length and an end, and wherein the lengths of the resin strings vary so that the ends of the resin strings form a non-rectilinear terminal curve, wherein the resin strings are oriented along the first direction and initially have grooves between these resin strings, wherein the grooves define a plurality of air discharge channels; and 
 (c) spreading out the deposited resin by a press device substantially along the first direction in which the resin strings are oriented, wherein the non-rectilinear terminal curve is calculated to produce a substantially rectilinear resin front at the end of a spreading travel of the press device and to minimize resin waste at two lateral sides of the manufactured plate. 
 
     
     
       2. A card manufacturing method wherein a plurality of cards or card bodies are made in the form of a plate or strip that includes a plurality of electronic units and a resin that at least partially coats the plurality of electronic units, wherein each card or card body is eventually cut out of the plate or strip, wherein the method includes the steps of:
 (a) providing a plurality of electronic units arranged on a working surface or a sheet; 
 (b) depositing at least one part of a resin in liquid form over the plurality of electronic units by a plurality of nozzles in a resin feed installation, wherein during deposition of the at least one part of the resin, the plurality of nozzles undergoes a travel movement relative to the plurality of electronic units along a first direction so as to generate strings of resin on the plurality of electronic units, wherein the resin strings are oriented along the first direction and initially have grooves between these resin strings, wherein the grooves define a plurality of air discharge channels, wherein the width of at least two grooves are not equal to provide a plurality of parallel resin strings with grooves of different widths between at least two adjacent pairs of resin strings; and 
 (c) spreading out the deposited resin by a press device substantially along the first direction in which the resin strings are oriented, wherein the grooves of different widths between at least two adjacent pairs of resin strings are calculated to produce a substantially rectilinear resin front at the end of a spreading travel of the press device and to minimize resin waste at two lateral sides of the manufactured plate. 
 
     
     
       3. A card manufacturing method wherein a plurality of cards or card bodies are made in the form of a plate or strip that includes a plurality of electronic units and a resin that at least partially coats the plurality of electronic units, wherein each card or card body is eventually cut out of the plate or strip, wherein the method includes the steps of:
 (a) providing a plurality of electronic units arranged on a working surface or a sheet; 
 (b) depositing at least one part of a resin in liquid form over the plurality of electronic units by a plurality of nozzles in a resin feed installation, wherein during deposition of the at least one part of the resin, the plurality of nozzles undergoes a movement relative to the plurality of electronic units along a first direction so as to generate strings of resin on the plurality of electronic units, wherein the width of at least two resin strings vary from each other, wherein the resin strings are oriented along the first direction and initially have grooves between these resin strings, wherein the grooves define a plurality of air discharge channels; and 
 (c) spreading out the deposited resin by a press device substantially along the first direction in which the resin strings are oriented, wherein the varied widths of the resin strings are calculated to produce a substantially rectilinear resin front at the end of a spreading travel of the press device and to minimize resin waste at two lateral sides of the manufactured plate.